Button-type battery constructions

ABSTRACT

Button-type battery electrode connection members, button-type battery constructions, and methods of establishing electrical connections with and between button-type batteries are described. In one implementation, an electrode connection member comprises an inner conductive surface, and outer peripheral conductive surface, and an intermediate conductive surface joined with and extending between the inner and outer surfaces. The connection member defines an internal volume which is sized to receive at least one thin-profile battery. In one aspect, the intermediate conductive surface tapers between the inner and outer surfaces. The taper enables more than one button-type battery to be mounted within the internal volume without the need for edge insulation material over one of the batteries to prevent grounding. The electrode connection member can be mounted on a substrate for providing a generally self-contained, space-conserving power source which can include more than one battery connected in a series electrical connection.

RELATED PATENT DATA

This patent resulted from a continuation application of U.S. patentapplication Ser. No. 09/274,550, now U.S. Pat. No. 6,207,317, filed Mar.23, 1999, entitled “Button-Type Battery Constructions” (as amended),naming Rickie C. Lake as inventor, the disclosure of which isincorporated by reference. Said U.S. patent application Ser. No.09/274,550, now U.S. Pat. No. 6,207,317, resulted from a divisionalapplication of U.S. patent application Ser. No. 08/954,224, filed Oct.20, 1997, entitled “Thin-Profile Battery Electrode Connection Members,Button-Type Battery Electrode Connection Members, Thin-Profile BatteryConstructions and Button-Type Battery Constructions” (as amended),naming Rickie C. Lake as inventor, now U.S. Pat. No. 5,998,061, issuedDec. 7, 1999, the disclosure of which is incorporated by reference.

TECHNICAL FIELD

This invention relates to thin-profile battery electrode connectionmembers, button-type battery electrode connection members, thin-profilebattery constructions, button-type battery constructions, and methods ofestablishing electrical connections with and between both thin-profilebatteries and button-type batteries.

BACKGROUND OF THE INVENTION

Thin-profile batteries are characterized by having thickness dimensionswhich are less than a maximum linear dimension of its anode or cathode.One type of thin-profile battery is a button-type battery. Suchbatteries, because of their compact size, permit electronic devices tobe built which themselves are very small or compact. When a highervoltage is needed in such devices, the batteries can be stacked orcascaded with one another to achieve a series electrical connection.When the electrical devices with which such batteries are used are smallin dimension, it is desirable to configure one or more of the batteriesin such a way as to conserve or minimize the space requirementsnecessary to achieve a desirable electrical connection between thebatteries and other components of the device.

This invention arose out of concerns associated with improving thestructures and methods through which thin-profile or button-typebatteries are interconnected with one another and with electricaldevices.

SUMMARY OF THE INVENTION

Thin-profile battery electrode connection members, button-type batteryelectrode connection members, thin-profile battery constructions,button-type battery constructions, and methods of establishingelectrical connections with and between both thin-profile batteries andbutton-type batteries are described. In one implementation, an electrodeconnection member comprises an inner conductive surface, and outerperipheral conductive surface, and an intermediate conductive surfacejoined with and extending between the inner and outer surfaces. Theconnection member defines an internal volume which is sized to receiveat least one thin-profile battery. In one aspect, the intermediateconductive surface tapers between the inner and outer surfaces. Thetaper enables more than one thin-profile battery to be mounted withinthe internal volume without the need for edge insulation material overone of the batteries to prevent grounding. The electrode connectionmember can be mounted on a substrate for providing a generallyself-contained, space-conserving power source which can include morethan one battery connected in a series electrical connection.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below withreference to the following accompanying drawings.

FIG. 1 is a side sectional view of an electrode connection member formedin accordance with one aspect of the invention.

FIG. 2 is a top plan view of the FIG. 1 electrode connection member.

FIG. 3 is a side sectional view of an electrode connection member formedin accordance with another aspect of the invention.

FIG. 4 is a side sectional view of the FIG. 1 electrode connectionmember within which a thin-profile battery is received.

FIG. 5 is a side sectional view of an electrode connection member whichis formed in accordance with an other aspect of the invention and withinwhich two thin-profile batteries are received.

FIG. 6 is a view of the FIG. 4 electrode connection member mounted on asubstrate.

FIG. 7 is a view of the FIG. 5 electrode connection member mounted on asubstrate .

FIG. 8 is a view of an exemplary electronic device which incorporates anelectrode connection member and battery stack in accordance with theinvention.

FIG. 9 is a view which is taken along line 9—9 in FIG. 1.

FIG. 10 is a view which is taken along line 10—10 in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This disclosure of the invention is submitted in furtherance of theconstitutional purposes of the U.S. Patent Laws “to promote the progressof science and useful arts” (Article 1, Section 8).

Referring to FIGS. 1, 2, 9, and 10, a connection member or container isshown generally at 20 and is configured for use with at least onethin-profile or button-type battery. Connection member 20 can compriseany suitable conductive material such as nickel foil, stainless steelsheet, metal screen mesh, and the like, and can be formed by stamping,etching, drawing, or molding any of such materials. Connection member 20includes an inner conductive electrode connection surface 22 which issized to receive and form an electrical connection with a batteryelectrode surface as will become apparent below. A battery electrodesurface is mounted over or atop surface 22 and can be fixed in placewith conductive epoxy. Accordingly, surface 22 can be considered as amounting surface. At least a portion of surface 22 is generally planarand is oriented within a mounting surface plane P₁, Connection surface22 has an outermost boundary edge 24 which is generally circular inshape.

A conductive side or intermediate surface 26 is provided and is joinedwith connection surface 22 proximate outermost boundary edge 24. Theoutermost boundary edge defines a joinder location between surfaces 22,26, with both surfaces extending generally away therefrom. In theillustrated example, surface 26 tapers to extend generally outwardlyfrom connection surface 22 and define a generally frustum-shaped sidesurface.

An outer peripheral conductive surface or rim 28 is provided and isjoined with side surface 26 proximate a joinder location 30. Outersurface or rim 28 defines an opening into an internal volume 32 which isdefined by connection surface 22 and side surface 26. Internal volume 32is sized to receive a substantial portion of at least one thin-profileor button-type battery. Side surface 26 tapers generally outwardly fromjoinder location 24 toward joinder location 30. The rim defines aterminus of side surface 26. Outer surface 28 is oriented within a planeP₂ which is generally parallel with plane P₁ Side surface 26 includes atleast a portion which extends away from plane P₁ at an angle θ which isgenerally oblique relative thereto. Other angles θ are of coursepossible. In the illustrated example, a substantial portion of sidesurface 26 extends away at the angle θ. Surface 26 is dimensioned toachieve substantial alignment between outer surface 28 and a batteryelectrode surface of a thin-profile or button-type battery which isreceived within connection member 20.

In one aspect, connection member 20 has a thickness dimension t adjacentinner conductive surface 22 and in a direction A which is normal toplane P₁, Outer surface or rim 28 includes first and second boundaryedges 34, 36 respectively, which have a minimum separation distance dtherebetween. First and second boundary edges 34, 36 are generallycircular in shape and concentric with one another. In the illustratedexample, minimum separation distance d is greater than the thicknessdimension t of connection member 20.

FIG. 3 shows a connection member 20 which is similar in construction tothe FIG. 1 connection member except that outer surface or rim 28 definesa minimum separation distance d which is approximately equal tothickness dimension t.

FIGS. 9 and 10 illustrate different cuts which are taken throughconnection member 20 of FIG. 1. FIG. 9 shows a first portion or cutcomprising side surface 26 which is taken through line 9—9 in FIG. 1.FIG. 10 shows a second portion or cut comprising side surface 26 whichis taken through line 10—10 in FIG. 1. The side surface portions boundrespective first and second areas inside surface 26 and within internalvolume 32 which lie in respective first and second planes. The first andsecond planes are spaced from one another and the areas definedtherewithin are different from one another. In the illustrated example,the first and second planes are generally parallel with one another andwith plane P₁. The first plane (FIG. 9) is disposed closer to connectionsurface 22 than the second plane (FIG. 10). In the illustrated example,the first area is less than the second area.

Referring to FIG. 4, an exemplary thin-profile battery comprising abutton-type battery 38 is placed or mounted on connection member 20 andreceived within internal volume 32. Battery 38 includes a pair ofterminal housing members which define a pair of outwardly-facingelectrodes 40, 42. Electrode 40 comprises the lid or anode electrode ofthe battery and electrode 42 comprises the can or cathode electrode ofthe battery. Side surface 26 is dimensioned to achieve substantialalignment of outer surface 28 and electrode surface 40. Such is observedas plane P₂ is seen to be generally coincident with surface 40.Electrode 42 is conductively received against surface 22 and accordinglyestablishes electrical communication between electrode surface 42 andconnection member 20. Accordingly, a single battery is provided andcomprises different respective surfaces with which electrical connectionis made with connection member 20, and substantial alignment is achievedwith outer surface 28. Conductive adhesion with epoxy or other suitablebonding techniques such as welding can be utilized to fixedly mountbattery 38 within connection member 20, if desired.

Referring to FIG. 5, a connection member which is formed in Isaccordance with an alternate embodiment of the present invention isshown generally at 20 a. Like numerals from the above-describedembodiment are utilized where appropriate, with differences beingindicated by the suffix “a” or with different numerals. Accordingly,mounting surface 22 a and side surface 26 a define an internal volume 32a which is sized to receive substantial portions of two thin-profilebatteries 44, 46. For purposes of the ongoing discussion, battery 44comprises a first battery and battery 46 comprises a second battery. Thebatteries are oriented in a stack, one atop the other, and can beconductively bonded together if desired. Battery 44 includes a pair ofterminal housing members comprising lid and can terminals. The lid andcan terminals respectively define a pair of outwardly-facing batteryelectrode surfaces 48, 50. Battery 46 includes a pair of terminalhousing members comprising lid and can terminals. The lid 5 and canterminals respectively define a pair of outwardly facing batteryelectrode surfaces 52, 54. Side surface 26 a is dimensioned to achievesubstantial alignment of outer surface 28 a and battery electrodesurface 52. Accordingly, substantial alignment is achieved with anelectrode surface of a different battery from which desired electricalconnection is made with connection surface 22 a.

Side surface 26 a of connection member 20 a extends away from connectionsurface 22 a sufficiently to bring at least a portion of the sidesurface into abutting physical engagement with only one of the batteriesreceived within internal volume 32 a. In the illustrated example, suchabutting engagement is achieved with battery 44 only and not withbattery 46 by imparting a desired degree of taper to side surface 26 a.The illustrated side surface 26 a is generally frustum-shaped which issimilar to the one-battery embodiment of FIG. 4. By virtue of theangularity of side surface 26 a relative to surface 22 a, no electricalinsulation is necessary to protect battery 46 from undesirably groundingagainst the side surface. Such insulation can, however, be provided ifdesired.

FIGS. 6 and 7 show a substrate portion 56 having a generally planarsubstrate surface 58. The substrate can comprise a printed circuitsubstrate, i.e. printed circuit board, or a flexible circuit board andthe like. A pair of spaced electrical contacts or contact pads 60, 62are supported. by substrate 56. Contact 60 comprises two differentspaced portions which are each laterally spaced from contact 62.Exemplary materials for the contact pads include screen orstencil-printed conductive materials such as copper or conductiveprinted thick film (PTF). The material from which contacts 60, 62 areformed can be either recessed within substrate 56 or disposed atop thesubstrate. In the context of this document, both constructions are seento provide a generally planar outer surface adjacent which one or morebatteries can be mounted or received.

Outer surfaces or rims 28 (FIG. 6), 28 a (FIG. 7) are disposed againstsubstrate surface 58. Surface 58 substantially encloses the battery orbatteries received within the respective internal volumes 32, 32 a.Accordingly, containers 20, 20 a and substrate surface 58 definerespective enclosures 64, 64 a inside of which a battery or batteriesare received. Electrode surfaces 40 (FIG. 6), 52 (FIG. 7) areconductively received against contact pad 62, while outer surfaces 28,28 a are conductively received against contact pad 60. Outer surfaces28, 28 a can be conductively bonded to the contact pads by conductiveepoxy. Accordingly an electrical circuit connection is formed.

Referring to FIG. 7, batteries 44, 46 are conductively connectedtogether in a stack which defines a series electrical connection. Afirst electrical connection is defined between electrode surface 48 ofbattery 44 and electrode surface 54 of battery 46. Such electricalconnection can arise from a mere physical engagement of the batteries orthrough the application of a suitable conductive epoxy material or otherbonding agent to effectively conductively bond the two together. Asecond electrical connection is provided between electrode surface 50 ofbattery 44 and electrode surface 52 of battery 46. In the illustratedexample, the second electrical connection is provided through therespective contact pads which operably connect with circuitry which isexternal to the batteries. An exemplary arrangement is shown in FIG. 8where a single integrated circuitry chip 66 is mounted over substrate56. Connection member 20 a is received over the substrate and operablymounted thereon so that the batteries are placed into electricalcommunication with chip 66. The contact pads are defined by conductivetraces which form, together with chip 66, the second electricalconnection mentioned above. In the illustrated and preferred embodiment,chip 66 is configured for wireless radio frequency communication. Anexemplary chip is described is U.S. patent application Ser. No.08/705,043, now U.S. Pat. No. 6,130,602, which names James O'Toole, JohnR. Tuttle, Mark E. Tuttle, Tyler Lowrey, Kevin Devereaux, George Pax,Brian Higgins, Shu-Sun Yu, David Ovard and Robert Rotzoll as inventors,which was filed on Aug. 29, 1996, is assigned to the assignee of thispatent application, and is fully incorporated herein by reference.

In compliance with the statute, the invention has been described inlanguage more or less specific as to structural and methodical features.It is to be understood, however, that the invention is not limited tothe specific features shown and described, since the means hereindisclosed comprise preferred forms of putting the invention into effect.The invention is, therefore, claimed in any of its forms ormodifications within the proper scope of the appended claimsappropriately interpreted in accordance with the doctrine ofequivalents.

What is claimed is:
 1. A button-type battery construction comprising: aconnection member comprising a conductive button-type battery electrodeconnection surface, the connection member also comprising a conductivegenerally frustum-shaped side surface integrally joined with theconnection surface, the electrode connection surface and thefrustum-shaped side surface taken together alone defining an internalvolume sized to receive at least most all of at least one button-typebattery; and at least one button-type battery received within theinternal volume and in electrical contact with the conductive connectionsurface.
 2. The button-type battery construction of claim 1, wherein theside surface comprises a rim which defines an opening into the internalvolume and further comprising a surface disposed against the rim andsubstantially enclosing the at least one button-type battery within theinternal volume.
 3. The button-type battery construction of claim 2,wherein the surface which is disposed against the rim comprises agenerally planar surface portion adjacent and engaged with the at leastone battery, the surface portion comprising an electrical contact pad inelectrical communication with the battery.
 4. The button-type batteryconstruction of claim 1 further comprising another button-type batteryreceived within the internal volume and operably connected with the atleast one button-type battery in a series connection, wherein the sidesurface comprises a rim which defines an opening into the internalvolume and further comprising a surface disposed against the rim andsubstantially enclosing the button-type batteries.
 5. The button-typebattery construction of claim 4, wherein the button-type batteriescomprise respective positive and negative electrode surfaces and whereinthe surface which is disposed against the rim is comprises a pair ofspaced apart electrical contact pads thereon, one of the contact padsbeing in physical and electrical connection with one of the positive ornegative electrode surfaces of one of the button-type batteries, theother of the contact pads being in physical and electrical connectionwith the connection member.
 6. The button-type battery construction ofclaim 1 wherein said internal volume is sized to receive at least mostall of each of at least two button-type batteries, and comprising atleast most all of at least two button-type batteries received withinsaid internal volume.
 7. The button-type battery construction of claim 1wherein said internal volume is sized to receive all of each of at leasttwo button type batteries, and comprising all of at least twobutton-type batteries received within said internal volume.
 8. Thebutton-type battery construction of claim 1 wherein said internal volumeis sized to receive all of only a single button type battery, andcomprising all of only a single button type battery received within saidinternal volume.